CA2525365A1 - Polymerization catalyst for preparing polyesters, preparation of polyethylene terephthalate and use of polymerization catalyst - Google Patents
Polymerization catalyst for preparing polyesters, preparation of polyethylene terephthalate and use of polymerization catalyst Download PDFInfo
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- CA2525365A1 CA2525365A1 CA002525365A CA2525365A CA2525365A1 CA 2525365 A1 CA2525365 A1 CA 2525365A1 CA 002525365 A CA002525365 A CA 002525365A CA 2525365 A CA2525365 A CA 2525365A CA 2525365 A1 CA2525365 A1 CA 2525365A1
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- Prior art keywords
- polymerization catalyst
- aluminium
- acetate
- ethylene glycol
- polyethylene terephthalate
- Prior art date
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- Abandoned
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- 239000005020 polyethylene terephthalate Substances 0.000 title claims abstract description 21
- -1 polyethylene terephthalate Polymers 0.000 title claims abstract description 20
- 239000002685 polymerization catalyst Substances 0.000 title claims abstract description 20
- 229920000728 polyester Polymers 0.000 title claims abstract description 18
- 229920000139 polyethylene terephthalate Polymers 0.000 title claims abstract description 18
- 238000002360 preparation method Methods 0.000 title claims description 6
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 claims abstract description 63
- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 claims abstract description 22
- WOZVHXUHUFLZGK-UHFFFAOYSA-N dimethyl terephthalate Chemical compound COC(=O)C1=CC=C(C(=O)OC)C=C1 WOZVHXUHUFLZGK-UHFFFAOYSA-N 0.000 claims abstract description 18
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 claims abstract description 17
- 229910021502 aluminium hydroxide Inorganic materials 0.000 claims abstract description 17
- 238000005809 transesterification reaction Methods 0.000 claims abstract description 15
- WCOATMADISNSBV-UHFFFAOYSA-K diacetyloxyalumanyl acetate Chemical compound [Al+3].CC([O-])=O.CC([O-])=O.CC([O-])=O WCOATMADISNSBV-UHFFFAOYSA-K 0.000 claims abstract description 13
- 150000002148 esters Chemical class 0.000 claims abstract description 10
- 238000006068 polycondensation reaction Methods 0.000 claims abstract description 10
- 238000006116 polymerization reaction Methods 0.000 claims abstract description 7
- BTVWZWFKMIUSGS-UHFFFAOYSA-N dimethylethyleneglycol Natural products CC(C)(O)CO BTVWZWFKMIUSGS-UHFFFAOYSA-N 0.000 claims abstract description 5
- GGUBFICZYGKNTD-UHFFFAOYSA-N triethyl phosphonoacetate Chemical compound CCOC(=O)CP(=O)(OCC)OCC GGUBFICZYGKNTD-UHFFFAOYSA-N 0.000 claims description 14
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 claims description 13
- 238000000034 method Methods 0.000 claims description 10
- 238000006243 chemical reaction Methods 0.000 claims description 9
- DQWPFSLDHJDLRL-UHFFFAOYSA-N triethyl phosphate Chemical group CCOP(=O)(OCC)OCC DQWPFSLDHJDLRL-UHFFFAOYSA-N 0.000 claims description 9
- 239000000725 suspension Substances 0.000 claims description 7
- 239000007858 starting material Substances 0.000 claims description 4
- 230000032050 esterification Effects 0.000 claims description 2
- 238000005886 esterification reaction Methods 0.000 claims description 2
- 239000011541 reaction mixture Substances 0.000 claims description 2
- 239000000306 component Substances 0.000 claims 6
- 239000003054 catalyst Substances 0.000 abstract description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-M hydroxide Chemical compound [OH-] XLYOFNOQVPJJNP-UHFFFAOYSA-M 0.000 abstract 1
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 12
- ADCOVFLJGNWWNZ-UHFFFAOYSA-N antimony trioxide Chemical compound O=[Sb]O[Sb]=O ADCOVFLJGNWWNZ-UHFFFAOYSA-N 0.000 description 10
- 229940093476 ethylene glycol Drugs 0.000 description 9
- 239000000178 monomer Substances 0.000 description 8
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 6
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 6
- 229920000642 polymer Polymers 0.000 description 5
- 239000002253 acid Substances 0.000 description 4
- 239000000835 fiber Substances 0.000 description 4
- 229910001679 gibbsite Inorganic materials 0.000 description 4
- 229910052751 metal Inorganic materials 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- 239000002904 solvent Substances 0.000 description 4
- 150000002009 diols Chemical class 0.000 description 3
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- MHCVCKDNQYMGEX-UHFFFAOYSA-N 1,1'-biphenyl;phenoxybenzene Chemical compound C1=CC=CC=C1C1=CC=CC=C1.C=1C=CC=CC=1OC1=CC=CC=C1 MHCVCKDNQYMGEX-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 241001467084 Nilaparvata lugens reovirus Species 0.000 description 2
- 150000007513 acids Chemical class 0.000 description 2
- VSCWAEJMTAWNJL-UHFFFAOYSA-K aluminium trichloride Chemical compound Cl[Al](Cl)Cl VSCWAEJMTAWNJL-UHFFFAOYSA-K 0.000 description 2
- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 description 2
- 238000009833 condensation Methods 0.000 description 2
- 230000005494 condensation Effects 0.000 description 2
- 239000013529 heat transfer fluid Substances 0.000 description 2
- 230000014759 maintenance of location Effects 0.000 description 2
- 239000011572 manganese Substances 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 239000000047 product Substances 0.000 description 2
- 238000009987 spinning Methods 0.000 description 2
- 238000003756 stirring Methods 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- BYEAHWXPCBROCE-UHFFFAOYSA-N 1,1,1,3,3,3-hexafluoropropan-2-ol Chemical group FC(F)(F)C(O)C(F)(F)F BYEAHWXPCBROCE-UHFFFAOYSA-N 0.000 description 1
- 239000004705 High-molecular-weight polyethylene Substances 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 230000002378 acidificating effect Effects 0.000 description 1
- 125000001931 aliphatic group Chemical group 0.000 description 1
- 150000001399 aluminium compounds Chemical class 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 150000008064 anhydrides Chemical class 0.000 description 1
- 229940077746 antacid containing aluminium compound Drugs 0.000 description 1
- 150000001805 chlorine compounds Chemical class 0.000 description 1
- 150000001868 cobalt Chemical class 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 239000008139 complexing agent Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000002425 crystallisation Methods 0.000 description 1
- 230000008025 crystallization Effects 0.000 description 1
- 230000006735 deficit Effects 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 150000001991 dicarboxylic acids Chemical class 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 231100000053 low toxicity Toxicity 0.000 description 1
- 229940071125 manganese acetate Drugs 0.000 description 1
- UOGMEBQRZBEZQT-UHFFFAOYSA-L manganese(2+);diacetate Chemical compound [Mn+2].CC([O-])=O.CC([O-])=O UOGMEBQRZBEZQT-UHFFFAOYSA-L 0.000 description 1
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 238000012643 polycondensation polymerization Methods 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000004753 textile Substances 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
- C08G63/78—Preparation processes
- C08G63/82—Preparation processes characterised by the catalyst used
- C08G63/84—Boron, aluminium, gallium, indium, thallium, rare-earth metals, or compounds thereof
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F4/00—Polymerisation catalysts
- C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
- C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
- C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
- C08F4/62—Refractory metals or compounds thereof
- C08F4/64—Titanium, zirconium, hafnium or compounds thereof
- C08F4/642—Component covered by group C08F4/64 with an organo-aluminium compound
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
- C08G63/78—Preparation processes
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
- C08G63/78—Preparation processes
- C08G63/82—Preparation processes characterised by the catalyst used
Landscapes
- Chemical & Material Sciences (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Polyesters Or Polycarbonates (AREA)
Abstract
The invention relates to a polymerization catalyst for preparing polyesters.
The catalyst containsaluminium hydroxide and/or aluminium acetate as a first component and at least one phosphoric or phosphonic ester as a second component. The invention also relates to a polymerization process for preparing polyethylene terephthalate from dimethyl terephthalate and ethylene glycol or terephthalic acid and ethylene glycol by transesterification and polycondensation respectively. The invention further relates to the use of aluminium hydroxide and/or aluminium acetate in combination with at least one phosphoric or phosphonic ester as polymerization catalyst when preparing polyesters by polycondensation or transesterification.
The catalyst containsaluminium hydroxide and/or aluminium acetate as a first component and at least one phosphoric or phosphonic ester as a second component. The invention also relates to a polymerization process for preparing polyethylene terephthalate from dimethyl terephthalate and ethylene glycol or terephthalic acid and ethylene glycol by transesterification and polycondensation respectively. The invention further relates to the use of aluminium hydroxide and/or aluminium acetate in combination with at least one phosphoric or phosphonic ester as polymerization catalyst when preparing polyesters by polycondensation or transesterification.
Description
Polymerization catalyst for preparing polyesters, preparation of polyethylene terephthalate and use of polymerization catalyst The invention relates to a polymerization catalyst for preparing polyesters, especially polyethylene terephthalate.
Linear polyesters can be prepared by condensation polymerization between dicarboxylic acids or their functional derivatives such as anhydrides and chlorides on the one hand and diols on the other. Whereas linear polyesters from aliphatic dicarboxylic .acids cannot be used directly because of their low softening range, the linear polyesters of terephthalic acid have achieved immense commercial significance as textile fibres or moulding materials. Of these polyesters of terephthalic acid, polyethylene terephthalate is the most important.
Polyethylene terephthalate can be prepared by a poly-condensation of terephthalic acid and ethylene glycol.
The polycondensation is carried out in two stages. In the first stage, terephthalic acid is esterified with an excess of glycol at 190-280°C under nitrogen. Glycol ester is formed as an intermediate. In the second stage, a condensation is carried out at reduced pressure and a temperature of 290°C for example in the presence of a metal oxide catalyst. The excess glycol released in the process is distilled off. The viscous condensation mass is squeezed off on attainment of the desired viscosity, cooled in water and chipped. Poly-ethylene terephthalate consists of chain molecules having a molar mass of 15 000 to 30 000 g/mol. They are partly crystalline, and polyethylene terephthalate can attain a crystallinity of 30o to 400. Owing to its low rate of crystallization, it can also be made in an amorphous grade, by quenching.
As well as from terephthalic acid and ethylene glycol, polyethylene terephthalate may also be prepared by transesterification of dimethyl terephthalate and ethy-lene glycol.
US-A-5 674 801 discloses a process for preparing poly-ethylene terephthalate by utilizing a polymerization catalyst comprising a cobalt salt in combination with aluminium chloride, aluminium hydroxide, aluminium acetate or aluminium hydroxychloride.
High molecular weight polyethylene terephthalate often has undesirable colour due to the presence of catalyst residues from the manufacture of terephthalic acid.
These catalyst residues include manganese, zinc, iron and molybdenum. The cited US Patent US-A-5 674 801 describes sequestering the metal catalyst residues with phosphoric acid to obtain a final product which ideally is colourless or white. It is known that many metals combine with phosphoric acid in a strongly acidic medium to form heteropolyacids. It is believed that the sequestering of the metal impurities by phosphoric acid is based on this reaction. The disadvantage with this is the use of phosphoric acid, a strong and very aggressive acid.
It is an object of the present invention to provide a polymerization catalyst for preparing polyesters and a polymerization process for preparing polyethylene tere-phthalate whereby it is possible to prepare polyesters and polyethylene terephthalate in particular which do not exhibit troublesome colour and are instead ideally colourless or white. The use of aggressive acids shall be avoided. It is a further object of the present invention to prepare polyesters which have low levels of diethylene glycol and carboxyl groups in the polymer and which, furthermore, possess very good spinnability, leaving no deposits at the spinnerets, and good thermal stability.
Linear polyesters can be prepared by condensation polymerization between dicarboxylic acids or their functional derivatives such as anhydrides and chlorides on the one hand and diols on the other. Whereas linear polyesters from aliphatic dicarboxylic .acids cannot be used directly because of their low softening range, the linear polyesters of terephthalic acid have achieved immense commercial significance as textile fibres or moulding materials. Of these polyesters of terephthalic acid, polyethylene terephthalate is the most important.
Polyethylene terephthalate can be prepared by a poly-condensation of terephthalic acid and ethylene glycol.
The polycondensation is carried out in two stages. In the first stage, terephthalic acid is esterified with an excess of glycol at 190-280°C under nitrogen. Glycol ester is formed as an intermediate. In the second stage, a condensation is carried out at reduced pressure and a temperature of 290°C for example in the presence of a metal oxide catalyst. The excess glycol released in the process is distilled off. The viscous condensation mass is squeezed off on attainment of the desired viscosity, cooled in water and chipped. Poly-ethylene terephthalate consists of chain molecules having a molar mass of 15 000 to 30 000 g/mol. They are partly crystalline, and polyethylene terephthalate can attain a crystallinity of 30o to 400. Owing to its low rate of crystallization, it can also be made in an amorphous grade, by quenching.
As well as from terephthalic acid and ethylene glycol, polyethylene terephthalate may also be prepared by transesterification of dimethyl terephthalate and ethy-lene glycol.
US-A-5 674 801 discloses a process for preparing poly-ethylene terephthalate by utilizing a polymerization catalyst comprising a cobalt salt in combination with aluminium chloride, aluminium hydroxide, aluminium acetate or aluminium hydroxychloride.
High molecular weight polyethylene terephthalate often has undesirable colour due to the presence of catalyst residues from the manufacture of terephthalic acid.
These catalyst residues include manganese, zinc, iron and molybdenum. The cited US Patent US-A-5 674 801 describes sequestering the metal catalyst residues with phosphoric acid to obtain a final product which ideally is colourless or white. It is known that many metals combine with phosphoric acid in a strongly acidic medium to form heteropolyacids. It is believed that the sequestering of the metal impurities by phosphoric acid is based on this reaction. The disadvantage with this is the use of phosphoric acid, a strong and very aggressive acid.
It is an object of the present invention to provide a polymerization catalyst for preparing polyesters and a polymerization process for preparing polyethylene tere-phthalate whereby it is possible to prepare polyesters and polyethylene terephthalate in particular which do not exhibit troublesome colour and are instead ideally colourless or white. The use of aggressive acids shall be avoided. It is a further object of the present invention to prepare polyesters which have low levels of diethylene glycol and carboxyl groups in the polymer and which, furthermore, possess very good spinnability, leaving no deposits at the spinnerets, and good thermal stability.
The present objects are achieved by a polymerization catalyst of the kind mentioned at the beginning that contains aluminium hydroxide and/or aluminium acetate as a first component and at least one phosphoric or phosphonic ester as a second component.
Of the aluminium compounds mentioned, aluminium hydroxide is preferable because of its low toxicity and because of its environmental compatibility.
The two components of the polymerization catalyst according to the invention can be present as a mixture.
However, to enable the polymerization catalyst to be used more flexibly, it is advantageous when the first and second components are separated in space and form a kit. In this case, the components can be mixed in the desired mixing ratios directly before use or be added to the polymerization batch in succession in the course of the preparation of a polyester.
Particularly advantageous second components have been determined to be triethyl phosphate and triethyl phosphonoacetate. It has been determined that these compounds are the best complexing agents for the troublesome metals.
Advantageously, the first component and/or the second component are present as a suspension or solution in mono- or diethylene glycol. This facilitates the handling of the catalyst. Since ethylene glycol is an important diol component for the preparation of polyesters, the use of this diol as a suspension or solution medium obviates the use of other solvents which would subsequently have to be removed from the system.
The invention also provides a polymerization process for preparing polyethylene terephthalate from dimethyl terephthalate and ethylene glycol or terephthalic acid and ethylene glycol by transesterification and poly-condensation respectively. According to the invention, the reaction of the starting materials is carried out in the presence of aluminium hydroxide and/or aluminium acetate and of at least one phosphoric or phosphonic ester.
The aluminium hydroxide and/or aluminium acetate is used advantageously in a concentration of 50 to 3 500 ppm and preferably of 1 000 to 2 500 based on the final polyethylene terephthalate product. A
concentration of less than 50 ppm is not sufficiently effective, and a concentration of more than 3 500 ppm is not necessary because it yields no further benefit.
Advantageously, in the process according to the inven-tion, the phosphoric and phosphonic esters used are triethyl phosphate and triethyl phosphonoacetate respectively.
The concentration of the triethyl phosphate and/or triethyl phosphonoacetate is advantageously 5 to 150 ppm based on the polyethylene terephthalate to be prepared. In the polymerization process according to the invention, advantageously the aluminium hydroxide and/or aluminium acetate is added to the reaction mixture as a 5 to 50o suspension in ethylene glycol before the start of the reaction and the reaction of the starting materials is advantageously carried out at a temperature of 270 to 300°C at a pressure of 13 332 Pa to 133.32 Pa. These conditions lead to favourable rates of reaction.
When the polyethylene terephthalate is prepared by direct polycondensation of terephthalic acid and ethylene glycol, the triethyl phosphate and/or the triethyl phosphonoacetate are advantageously added during the esterification. When, on the other hand, the polyethylene terephthalate is prepared by a trans-esterification of dimethyl terephthalate and ethylene glycol, the triethyl phosphate and/or the triethyl phosphonoacetate are advantageously not added until after the transesterification.
The invention also provides for the use of aluminium hydroxide and/or aluminium acetate in combination with at least one phosphoric or phosphonic ester as a poly-merization catalyst in the preparation of polyesters by polycondensation or transesterification.
The use of the polymerization catalyst according to the invention and the polymerization process according to the invention make it possible to prepare, without the use of aggressive phosphoric acid, polyesters and poly-ethylene terephthalate which are colourless to white and have a low level of diethylene glycol and of carboxyl groups in the polymer. The products possess very good spinnability, leaving no deposits at the spinnerets, and good thermal stability.
The invention will now be more particularly described with reference to an illustrative example:
1. Comparative example: standard process with antimony trioxide and FI3P04 Dimethyl terephthalate (DMT) is fed at 4 770 kg/h to plate 15 of a 23 plate transesterification column.
Monoethylene glycol (MEG) is fed at 2 950 kg/h onto plate 18. Together with the monoethylene glycol, 2.21 kg/h of Mn(CH3C00)2 x 4H20 in dissolved form are fed as a transesterification catalyst.
The column is heated by means of a heater utilizing a heat transfer fluid (Dowtherm registered trademark of Dow Chemical Co.). DMT and MEG react with each other at elevated temperature under the influence of the catalyst to form the monomer and methanol at a bottom temperature of 242 ~ 2°C. Methanol is condensed at the top of the column and partly refluxed to the column for the purpose of temperature control.
The bottom of the transesterification column is fed with a continuous 140 kg/h of antimony trioxide dissolved in MEG as a polymerization catalyst. This rate corresponds to 3.35 kg/h of Sb~03.
The monomer produced in the bottom is then transferred through the monomer line into the prepolymerization column. 6.0 1/h of loo phosphoric acid in MEG, which corresponds to 0.714 kg/h of H3P04, is injected into the monomer line to deactivate the manganese acetate.
Furthermore, 54 1/h of a 20o Ti02 suspension in MEG, which corresponds to 13.8 kg/h of Ti02, is injected into the monomer line as a delustrant. The two substances undergo intensive mixing with the monomer.
The monomer starts to polymerize in the 16 plate prepolymerization column at up to 292°C under the influence of the antimony trioxide, heat supplied by means of a heater heated by means of a heat transfer fluid (Dowtherm°) and a vacuum down to 2 133.12 Pa. 950 of the MEG released in the course of this reaction is condensed at the top of the prepolymerization column and withdrawn from the process.
The prepolymer then passes by gravity and pressure difference through a siphoning line into a horizontally disposed kettle equipped with a stirrer consisting of a multiplicity of discs. The prepolymer is then poly-merized at 295°C and 266.64 Pa to the desired viscosity (= average molecular weight) by further withdrawal of MEG. The viscosity is adjusted by vacuum control to an NLRV of 22.5, which corresponds to an IV (intrinsic viscosity) of about 0.65.
NLRV, a measure of relative viscosity, is the ratio at 25°C of the flow times in a capillary viscometer for the pure solvent and a solution. The solution is 4.75 weight o of polymer in solvent. The solvent is hexafluoroisopropanol.
The ready-prepared polymer is subsequently pumped at 4 788 kg/h to a spinning machine and at 290°C through spinneret plates to form 15 dtex fibre having a single hole void content of 20o and air quenched to below 50°C.
Thereafter, the filaments are wet-drawn to 6.1 dtex, crimped, relaxed, cut and baled.
2. Inventive example with Al(OH)3 and triethyl phos-phonoacetate (TEPA) The standard process with antimony trioxide and H3P04 is repeated in the same equipment and under the same operating conditions except that the addition of antimony trioxide and H3P04 is omitted.
Instead, 6.0 kg/h of 30% TEPA in MEG, which corresponds to 1.8 kg/h of TEPA, is added to the bottom of the transesterification column.
To prepare the mixture, TEPA having a purity of at least 98 o and a maximum acid number of 2 . 0 ~ mg of KOH/g was added at room temperature to the appropriate amount of MEG with stirring.
70 kg/h of a 20% suspension of A1(OH)3 in MEG, which corresponds to 14 kg/h of Al(OH)3, are injected into the monomer line.
Of the aluminium compounds mentioned, aluminium hydroxide is preferable because of its low toxicity and because of its environmental compatibility.
The two components of the polymerization catalyst according to the invention can be present as a mixture.
However, to enable the polymerization catalyst to be used more flexibly, it is advantageous when the first and second components are separated in space and form a kit. In this case, the components can be mixed in the desired mixing ratios directly before use or be added to the polymerization batch in succession in the course of the preparation of a polyester.
Particularly advantageous second components have been determined to be triethyl phosphate and triethyl phosphonoacetate. It has been determined that these compounds are the best complexing agents for the troublesome metals.
Advantageously, the first component and/or the second component are present as a suspension or solution in mono- or diethylene glycol. This facilitates the handling of the catalyst. Since ethylene glycol is an important diol component for the preparation of polyesters, the use of this diol as a suspension or solution medium obviates the use of other solvents which would subsequently have to be removed from the system.
The invention also provides a polymerization process for preparing polyethylene terephthalate from dimethyl terephthalate and ethylene glycol or terephthalic acid and ethylene glycol by transesterification and poly-condensation respectively. According to the invention, the reaction of the starting materials is carried out in the presence of aluminium hydroxide and/or aluminium acetate and of at least one phosphoric or phosphonic ester.
The aluminium hydroxide and/or aluminium acetate is used advantageously in a concentration of 50 to 3 500 ppm and preferably of 1 000 to 2 500 based on the final polyethylene terephthalate product. A
concentration of less than 50 ppm is not sufficiently effective, and a concentration of more than 3 500 ppm is not necessary because it yields no further benefit.
Advantageously, in the process according to the inven-tion, the phosphoric and phosphonic esters used are triethyl phosphate and triethyl phosphonoacetate respectively.
The concentration of the triethyl phosphate and/or triethyl phosphonoacetate is advantageously 5 to 150 ppm based on the polyethylene terephthalate to be prepared. In the polymerization process according to the invention, advantageously the aluminium hydroxide and/or aluminium acetate is added to the reaction mixture as a 5 to 50o suspension in ethylene glycol before the start of the reaction and the reaction of the starting materials is advantageously carried out at a temperature of 270 to 300°C at a pressure of 13 332 Pa to 133.32 Pa. These conditions lead to favourable rates of reaction.
When the polyethylene terephthalate is prepared by direct polycondensation of terephthalic acid and ethylene glycol, the triethyl phosphate and/or the triethyl phosphonoacetate are advantageously added during the esterification. When, on the other hand, the polyethylene terephthalate is prepared by a trans-esterification of dimethyl terephthalate and ethylene glycol, the triethyl phosphate and/or the triethyl phosphonoacetate are advantageously not added until after the transesterification.
The invention also provides for the use of aluminium hydroxide and/or aluminium acetate in combination with at least one phosphoric or phosphonic ester as a poly-merization catalyst in the preparation of polyesters by polycondensation or transesterification.
The use of the polymerization catalyst according to the invention and the polymerization process according to the invention make it possible to prepare, without the use of aggressive phosphoric acid, polyesters and poly-ethylene terephthalate which are colourless to white and have a low level of diethylene glycol and of carboxyl groups in the polymer. The products possess very good spinnability, leaving no deposits at the spinnerets, and good thermal stability.
The invention will now be more particularly described with reference to an illustrative example:
1. Comparative example: standard process with antimony trioxide and FI3P04 Dimethyl terephthalate (DMT) is fed at 4 770 kg/h to plate 15 of a 23 plate transesterification column.
Monoethylene glycol (MEG) is fed at 2 950 kg/h onto plate 18. Together with the monoethylene glycol, 2.21 kg/h of Mn(CH3C00)2 x 4H20 in dissolved form are fed as a transesterification catalyst.
The column is heated by means of a heater utilizing a heat transfer fluid (Dowtherm registered trademark of Dow Chemical Co.). DMT and MEG react with each other at elevated temperature under the influence of the catalyst to form the monomer and methanol at a bottom temperature of 242 ~ 2°C. Methanol is condensed at the top of the column and partly refluxed to the column for the purpose of temperature control.
The bottom of the transesterification column is fed with a continuous 140 kg/h of antimony trioxide dissolved in MEG as a polymerization catalyst. This rate corresponds to 3.35 kg/h of Sb~03.
The monomer produced in the bottom is then transferred through the monomer line into the prepolymerization column. 6.0 1/h of loo phosphoric acid in MEG, which corresponds to 0.714 kg/h of H3P04, is injected into the monomer line to deactivate the manganese acetate.
Furthermore, 54 1/h of a 20o Ti02 suspension in MEG, which corresponds to 13.8 kg/h of Ti02, is injected into the monomer line as a delustrant. The two substances undergo intensive mixing with the monomer.
The monomer starts to polymerize in the 16 plate prepolymerization column at up to 292°C under the influence of the antimony trioxide, heat supplied by means of a heater heated by means of a heat transfer fluid (Dowtherm°) and a vacuum down to 2 133.12 Pa. 950 of the MEG released in the course of this reaction is condensed at the top of the prepolymerization column and withdrawn from the process.
The prepolymer then passes by gravity and pressure difference through a siphoning line into a horizontally disposed kettle equipped with a stirrer consisting of a multiplicity of discs. The prepolymer is then poly-merized at 295°C and 266.64 Pa to the desired viscosity (= average molecular weight) by further withdrawal of MEG. The viscosity is adjusted by vacuum control to an NLRV of 22.5, which corresponds to an IV (intrinsic viscosity) of about 0.65.
NLRV, a measure of relative viscosity, is the ratio at 25°C of the flow times in a capillary viscometer for the pure solvent and a solution. The solution is 4.75 weight o of polymer in solvent. The solvent is hexafluoroisopropanol.
The ready-prepared polymer is subsequently pumped at 4 788 kg/h to a spinning machine and at 290°C through spinneret plates to form 15 dtex fibre having a single hole void content of 20o and air quenched to below 50°C.
Thereafter, the filaments are wet-drawn to 6.1 dtex, crimped, relaxed, cut and baled.
2. Inventive example with Al(OH)3 and triethyl phos-phonoacetate (TEPA) The standard process with antimony trioxide and H3P04 is repeated in the same equipment and under the same operating conditions except that the addition of antimony trioxide and H3P04 is omitted.
Instead, 6.0 kg/h of 30% TEPA in MEG, which corresponds to 1.8 kg/h of TEPA, is added to the bottom of the transesterification column.
To prepare the mixture, TEPA having a purity of at least 98 o and a maximum acid number of 2 . 0 ~ mg of KOH/g was added at room temperature to the appropriate amount of MEG with stirring.
70 kg/h of a 20% suspension of A1(OH)3 in MEG, which corresponds to 14 kg/h of Al(OH)3, are injected into the monomer line.
To prepare the mixture, Al(OH)3 having a purity of at least 990, a water content of max 0.350, a maximum of 0.250 of soluble Na205 and an average particle size of 0.25 ~.~m was added to the appropriate amount of MEG at room temperature with stirring.
3. Table comparing standard and inventive example Parameter Standard Invention As-spun fibre colour Minolta colorimeter L colour, exclude 86.5 88.5 B colour, exclude 6.4 6.8 A colour, exclude 0.7 0.0 Analyses on polymer Mn in ppm 114 111 P in ppm 38 40 Sb in ppm 269 ~ 16*
Al(OH)3 in ppm 10* 3 053 Ti02 in o 0.289 0.288 DEG in a 0.63 0.64 Drawn fibre (fiberfill) Initial bulk in cm 10.0 10.3 Support bulk in cm 2.1 2.2 Tenacity in cN/dtex 2.6 2.9 Elongation in % 30 31 * detection limit of X-ray analyser used.
The material according to the invention showed no impairment in spinning operation (pack pressure or position failures).
No A1(OH)3 particles were detectable in the fibre cross-section.
s
3. Table comparing standard and inventive example Parameter Standard Invention As-spun fibre colour Minolta colorimeter L colour, exclude 86.5 88.5 B colour, exclude 6.4 6.8 A colour, exclude 0.7 0.0 Analyses on polymer Mn in ppm 114 111 P in ppm 38 40 Sb in ppm 269 ~ 16*
Al(OH)3 in ppm 10* 3 053 Ti02 in o 0.289 0.288 DEG in a 0.63 0.64 Drawn fibre (fiberfill) Initial bulk in cm 10.0 10.3 Support bulk in cm 2.1 2.2 Tenacity in cN/dtex 2.6 2.9 Elongation in % 30 31 * detection limit of X-ray analyser used.
The material according to the invention showed no impairment in spinning operation (pack pressure or position failures).
No A1(OH)3 particles were detectable in the fibre cross-section.
s
Claims (11)
1. Polymerization catalyst for preparing polyesters, containing aluminium hydroxide and/or aluminium acetate as a first component and at least one phosphoric or phosphonic ester as a second component.
2. Polymerization catalyst according to Claim 1, characterized in that the first and second com-ponents are separated in space and form a kit.
3. Polymerization catalyst according to Claim 1 or 2, characterized in that the second component is triethyl phosphate or triethyl phosphonoacetate.
4. Polymerization catalyst according to Claim 1-3, characterized in that the first component and/or the second component are present as a suspension or solution in mono- or diethylene glycol.
5. Polymerization process for preparing polyethylene terephthalate from dimethyl terephthalate and ethylene glycol or terephthalic acid and ethylene glycol by transesterification and polycondensation respectively, characterized in that the reaction of the starting materials is carried out in the presence of aluminium hydroxide and/or aluminium acetate and of at least one phosphoric or phos-phonic ester.
6. Process according to Claim 5, characterized in that the aluminium hydroxide and/or aluminium acetate is used in a concentration of 50 to 3 500 ppm based on the polyethylene terephthalate.
7. Process according to Claim 5 or 6, characterized in that the phosphoric and phosphonic esters used are triethyl phosphate and triethyl phosphono-acetate respectively.
8. Process according to Claim 7, characterized in that triethyl phosphate and/or triethyl phosphono-acetate are used in a concentration of 5 to 150 ppm based on the polyethylene terephthalate.
9. Process according to Claim 5 to 8, characterized in that the aluminium hydroxide and/or aluminium acetate is added to the reaction mixture as a 5 to 50% suspension in ethylene glycol before the start of the reaction and the reaction of the starting materials is carried out at a temperature of 270 to 300°C at a pressure of 13 332 Pa to 133.32 Pa.
10. Process according to Claim 5 to 9, characterized in that the triethyl phosphate and/or the triethyl phosphonoacetate are added before, during or after the esterification in the case of the polycon-densation of terephthalic acid and ethylene glycol and after the transesterification in the case of the transesterification of dimethyl terephthalate and ethylene glycol.
11. Use of aluminium hydroxide and/or aluminium acetate in combination with at least one phosphoric or phosphonic ester as a polymerization catalyst in the preparation of polyesters by polycondensation or transesterification.~
10~~
10~~
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE10322099.2 | 2003-05-15 | ||
| DE10322099A DE10322099A1 (en) | 2003-05-15 | 2003-05-15 | Polymerization catalyst for the production of polyesters, process for the preparation of polyethylene terephthalate and use of the polymerization catalyst |
| PCT/EP2004/005060 WO2004101645A1 (en) | 2003-05-15 | 2004-05-12 | Polymerization catalyst for preparing polyesters, preparation of polyethylene terephthalate and use of polymerization catalyst |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2525365A1 true CA2525365A1 (en) | 2004-11-25 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002525365A Abandoned CA2525365A1 (en) | 2003-05-15 | 2004-05-12 | Polymerization catalyst for preparing polyesters, preparation of polyethylene terephthalate and use of polymerization catalyst |
Country Status (15)
| Country | Link |
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| US (1) | US20060135740A1 (en) |
| EP (1) | EP1477506A1 (en) |
| JP (1) | JP2006528270A (en) |
| KR (1) | KR20060015258A (en) |
| CN (1) | CN1788033A (en) |
| BR (1) | BRPI0410397A (en) |
| CA (1) | CA2525365A1 (en) |
| DE (1) | DE10322099A1 (en) |
| HR (1) | HRP20050960A2 (en) |
| LT (1) | LT5352B (en) |
| LV (1) | LV13428B (en) |
| MA (1) | MA27856A1 (en) |
| MX (1) | MXPA05012076A (en) |
| RU (1) | RU2005135149A (en) |
| WO (1) | WO2004101645A1 (en) |
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| JP4670338B2 (en) * | 2004-12-17 | 2011-04-13 | 東洋紡績株式会社 | Polyester and method for producing polyester |
| CN100430428C (en) * | 2005-01-18 | 2008-11-05 | 中国科学院化学研究所 | Use of clay mineral as polyester polycondensation catalyst |
| US8557950B2 (en) | 2005-06-16 | 2013-10-15 | Grupo Petrotemex, S.A. De C.V. | High intrinsic viscosity melt phase polyester polymers with acceptable acetaldehyde generation rates |
| FR2888851A1 (en) * | 2005-07-25 | 2007-01-26 | Tergal Fibres Sa | CATALYTIC SYSTEM FOR THE MANUFACTURE OF POLYESTER BY POLYCONDENSATION, PROCESS FOR THE MANUFACTURE OF POLYESTER |
| US9267007B2 (en) | 2005-09-16 | 2016-02-23 | Grupo Petrotemex, S.A. De C.V. | Method for addition of additives into a polymer melt |
| US7932345B2 (en) | 2005-09-16 | 2011-04-26 | Grupo Petrotemex, S.A. De C.V. | Aluminum containing polyester polymers having low acetaldehyde generation rates |
| US7838596B2 (en) | 2005-09-16 | 2010-11-23 | Eastman Chemical Company | Late addition to effect compositional modifications in condensation polymers |
| US8431202B2 (en) | 2005-09-16 | 2013-04-30 | Grupo Petrotemex, S.A. De C.V. | Aluminum/alkaline or alkali/titanium containing polyesters having improved reheat, color and clarity |
| US7655746B2 (en) | 2005-09-16 | 2010-02-02 | Eastman Chemical Company | Phosphorus containing compounds for reducing acetaldehyde in polyesters polymers |
| JP4987334B2 (en) * | 2006-03-30 | 2012-07-25 | 三井化学株式会社 | Polyethylene terephthalate and method for producing the same |
| US7745368B2 (en) | 2006-07-28 | 2010-06-29 | Eastman Chemical Company | Non-precipitating alkali/alkaline earth metal and aluminum compositions made with organic hydroxyacids |
| US7709593B2 (en) | 2006-07-28 | 2010-05-04 | Eastman Chemical Company | Multiple feeds of catalyst metals to a polyester production process |
| US7709595B2 (en) | 2006-07-28 | 2010-05-04 | Eastman Chemical Company | Non-precipitating alkali/alkaline earth metal and aluminum solutions made with polyhydroxyl ether solvents |
| US8563677B2 (en) | 2006-12-08 | 2013-10-22 | Grupo Petrotemex, S.A. De C.V. | Non-precipitating alkali/alkaline earth metal and aluminum solutions made with diols having at least two primary hydroxyl groups |
| US20090186177A1 (en) * | 2008-01-22 | 2009-07-23 | Eastman Chemical Company | Polyester melt phase products and process for making the same |
| US20100069553A1 (en) * | 2008-09-18 | 2010-03-18 | Eastman Chemical Company | Polyester melt-phase compositions having improved thermo-oxidative stability, and methods of making and using them |
| WO2021172307A1 (en) * | 2020-02-28 | 2021-09-02 | 共栄社化学株式会社 | Thermosetting resin composition and transesterification reaction catalyst |
Family Cites Families (15)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3533973A (en) * | 1968-11-04 | 1970-10-13 | Fmc Corp | Polyester polycondensation in the presence of a catalytic amount of a trivalent aluminum salt |
| JPS57162721A (en) * | 1981-03-31 | 1982-10-06 | Toray Ind Inc | Production of polyester |
| JPH0637550B2 (en) * | 1988-04-19 | 1994-05-18 | 富士写真フイルム株式会社 | Polyester manufacturing method |
| US5596069A (en) * | 1995-06-08 | 1997-01-21 | E. I. Du Pont De Nemours And Company | Catalyst and process for producing catalyst |
| EP1016692B1 (en) * | 1997-09-03 | 2003-11-26 | Asahi Kasei Kabushiki Kaisha | Polyester resin composition |
| DE60016447T2 (en) * | 1999-08-24 | 2005-12-08 | Toyo Boseki K.K. | Polymerization catalysts for polyesters, polyesters produced therewith and processes for the production of polyesters |
| WO2001049771A1 (en) * | 2000-01-05 | 2001-07-12 | Toyo Boseki Kabushiki Kaisha | Polymerization catalyst for polyesters, polyesters produced with the same and process for producing polyesters |
| US6458915B1 (en) * | 2000-10-13 | 2002-10-01 | Eastman Chemical Company | Process for producing poly(1,4-cyclohexylenedimethylene 1,4-cyclohexanedicarboxylate) and the reactor grade polyester therefrom |
| JP3460709B2 (en) * | 2000-11-21 | 2003-10-27 | 東洋紡績株式会社 | Polyester polymerization catalyst, polyester produced using the same, and method for producing polyester |
| JP2002212833A (en) * | 2001-01-16 | 2002-07-31 | Toyobo Co Ltd | Polyester combined filament yarn |
| JP2002212277A (en) * | 2001-01-23 | 2002-07-31 | Toyobo Co Ltd | Wadding |
| JP4393004B2 (en) * | 2001-02-06 | 2010-01-06 | 三菱化学株式会社 | Polyester resin |
| US6489433B2 (en) * | 2001-02-23 | 2002-12-03 | E. I. Du Pont De Nemours And Company | Metal-containing composition and process therewith |
| JP3874172B2 (en) * | 2002-01-24 | 2007-01-31 | 東洋紡績株式会社 | Polyester production method |
| WO2003102079A1 (en) * | 2002-06-03 | 2003-12-11 | Toyo Boseki Kabushiki Kaisha | Polyester composition and packaging material comprising the same |
-
2003
- 2003-05-15 DE DE10322099A patent/DE10322099A1/en not_active Withdrawn
-
2004
- 2004-05-12 CN CNA2004800132039A patent/CN1788033A/en active Pending
- 2004-05-12 JP JP2006529786A patent/JP2006528270A/en active Pending
- 2004-05-12 MX MXPA05012076A patent/MXPA05012076A/en unknown
- 2004-05-12 EP EP04011224A patent/EP1477506A1/en not_active Withdrawn
- 2004-05-12 RU RU2005135149/04A patent/RU2005135149A/en not_active Application Discontinuation
- 2004-05-12 KR KR1020057021817A patent/KR20060015258A/en not_active Application Discontinuation
- 2004-05-12 WO PCT/EP2004/005060 patent/WO2004101645A1/en active Application Filing
- 2004-05-12 CA CA002525365A patent/CA2525365A1/en not_active Abandoned
- 2004-05-12 BR BRPI0410397-1A patent/BRPI0410397A/en not_active Application Discontinuation
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2005
- 2005-11-14 US US11/273,586 patent/US20060135740A1/en not_active Abandoned
- 2005-11-15 HR HR20050960A patent/HRP20050960A2/en not_active Application Discontinuation
- 2005-11-15 LV LVP-05-150A patent/LV13428B/en unknown
- 2005-12-09 LT LT2005105A patent/LT5352B/en not_active IP Right Cessation
- 2005-12-12 MA MA28654A patent/MA27856A1/en unknown
Also Published As
| Publication number | Publication date |
|---|---|
| EP1477506A1 (en) | 2004-11-17 |
| LT5352B (en) | 2006-07-25 |
| CN1788033A (en) | 2006-06-14 |
| MXPA05012076A (en) | 2006-06-23 |
| LT2005105A (en) | 2006-04-25 |
| LV13428B (en) | 2006-08-20 |
| KR20060015258A (en) | 2006-02-16 |
| RU2005135149A (en) | 2006-06-10 |
| JP2006528270A (en) | 2006-12-14 |
| HRP20050960A2 (en) | 2006-02-28 |
| US20060135740A1 (en) | 2006-06-22 |
| DE10322099A1 (en) | 2005-01-27 |
| WO2004101645A1 (en) | 2004-11-25 |
| MA27856A1 (en) | 2006-04-03 |
| BRPI0410397A (en) | 2006-07-04 |
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